Solar Panel Roof Mounting System Having Integrated Standoff

ABSTRACT

A solar panel roof mounting system, including: a first elongated member having a U-shaped or C-shaped channel therein; and a second elongated member having a U-shaped or C-shaped channel therein, wherein the second elongated member is received into the first elongated member such that the U-shaped or C-shaped channel in the second elongated member is elevated with respect to the U-shaped or C-shaped channel in the first elongated member.

RELATED APPLICATION

The present application claims priority to U.S. Provisional patent application Ser. No. 61/057,710, filed May 30, 2008 of same title.

TECHNICAL FIELD

The present invention relates to systems for mounting solar panels on a roof.

SUMMARY OF THE INVENTION

The present invention provides a novel system for mounting solar panels on a roof. In various aspects, the present invention provides a solar panel roof mounting system, comprising: a first elongated member having a U-shaped or C-shaped channel therein; and a second elongated member having a U-shaped or C-shaped channel therein, wherein the second elongated member is received into the first elongated member such that the U-shaped or C-shaped channel in the second elongated member is elevated with respect to the U-shaped channel in the first elongated member.

The first elongated member may be a cladded standoff. It may be made of Steel, Galvalume, Aluminum, Stainless steel, any other suitable metal, PVC or any other similar extrusion, and be cladded with TPO, PVC, Hypalon, EPDM, sprayed polyurethane foam, modified Bitumen, building roofing, or similar materials. The first elongated member may be connected to the roof by heat welding, fastening or ballasting. It is to be understood, however, that the present invention is not limited to any particular system of fastening.

The second elongated member may be made of Galvalume, Aluminum, Stainless steel, any other suitable metal, PVC or any other similar extrusion. The U-shaped or C-shaped channel in the second elongated member forms a cable tray when the second elongated member is positioned on top of the first elongated member.

Optional end plates may be dimensioned to connect onto the first and second elongated members and to cover an end of the U-shaped or C-shaped channel in the second elongated member. Preferably, the end plate is dimensioned to wrap around a side and front portion of a solar panel positioned on top of the second elongated member.

An optional center plate may be dimensioned to connect onto the first and second elongated members and to cover a portion of the U-shaped or C-shaped channel in the second elongated member. Preferably, the center plate is dimensioned to wrap around a side and front portion of two spaced apart solar panels that are positioned on top of the second elongated member.

The present invention also provides a method of mounting solar panels on a roof, comprising: mounting a first elongated member on a roof, the first elongated member having a U-shaped channel therein; mounting a second elongated member onto the first elongated member, the second elongated member having a U-shaped or C-shaped channel therein, wherein the U-shaped or C-shaped channel in the second elongated member is received into the U-shaped or C-shaped channel in the first U-shaped or C-shaped channel thereby forming a cable tray; positioning a solar panel on top of the second elongated member; and securing the solar panel onto the top of the second elongated member.

Securing the solar panel onto the top of the second elongated member may be done by wrapping an edge of a center plate around the solar panel; and connecting the center plate onto the second elongated member. Further steps include positioning a second solar panel on top of the second elongated member; and wrapping an opposite edge of a center plate around the second solar panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded perspective view of the present solar panel roof mount.

FIG. 1B is an assembled view corresponding to FIG. 1A.

FIG. 2A is an end perspective view of the present solar panel roof mount with a pair of solar panels mounted thereon, also showing a pair of end plates.

FIG. 2B is a top perspective view corresponding to FIG. 2A (showing three solar panels mounted onto the roof mount, where portions of the roof mount system are shown in dotted lines).

FIG. 2C is a close-up perspective view corresponding to a portion of the system shown in FIG. 2A.

FIG. 3A is a perspective view of a center plate.

FIG. 3B is a side elevation view of the center plate of FIG. 3A positioned on top of the roof mount system, between two solar panels.

FIG. 4 is a view similar to FIG. 1A, but instead having a C-shaped channel.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring first to FIGS. 1A and 1B, the present invention provides a solar panel roof mounting system 10. System 10 comprises: a first elongated member 20 having a U-shaped channel 25 therein; and a second elongated member 30 also having a U-shaped channel 35 therein. Second elongated member 30 is received down into first elongated member 20 (as shown by dotted lines in FIG. 1A) such that U-shaped channel 35 in second elongated member 30 is elevated with respect to the U-shaped channel 25 in first elongated member 20.

First elongated member 20 functions as a physical standoff, for raising a plurality of solar panels up off of a roof. First, elongated member 20 is fastened to the roof and then one or more solar panels are positioned on top of elongated member 20. This has the advantage of eliminating the use of a PV racking system, no or limited penetrations to the roof, more cost effective, faster installation, less actively on the roof, incorporate the cable tray, excellent weight distribution of the solar system on the roof, use all standard roofing fasteners and material to install the standoff and fit the panels.

First elongated member 20 may be secured directly to onto roof R by a variety of methods, including, but not limited to heat welding of an strip of membrane on the cladded or extruded member 20 and then welding to the roof membrane, adhering member 20 to the roof, fastening through member 20 in to the roof, using weights to ballast member 20 on the roof, bolting to the roof or a combination of the above. First elongated member 20 may be made of Steel, Galvalume, Aluminum, Stainless steel, any other suitable metal, (PVC or any other similar extrusion) and my be cladded with TPO, PVC, Hypalon, EPDM, sprayed polyurethane foam, modified Bitumen, building roofing, or similar roofing materials/membranes.

Second elongated member 30 is then received into the open top of first elongated member 20, with the U-shaped channel 35 in second elongated member 30 forming a “cable tray” that can be used to support cables running to/from the solar panels S1 and S2 (FIGS. 2A to 2C). An advantage of this design is that the cable tray formed in elevated channel 35 is raised above the roof R's surface. As such, it lifts the cables therein out of the way of any rain or run-off on the roof's surface. In addition, the cables are isolated from the elements, as the ends of channels 35 may also be covered (as will be shown).

As seen in FIGS. 1A to 2B, first and second elongated members 20 and 30 may comprise laterally extending portions 21 and 31 that are connected to one another. As illustrated, laterally extending portion 31 of second elongated member 30 is positioned on top of laterally extending portion 21 of first elongated member 20. Preferably, the laterally extending portions 21 an 31 of first and second elongated members 20 and 30 are interlocking. This interlocking may be further enhanced by having end portions 22 and 32.

FIGS. 2A to 2C shows solar panels 51 and S2 mounted onto a pair of mounting systems 10. It is to be understood that the present system can use a pair of systems 10 onto which solar panels S are mounted. However, in alternate embodiments, additional systems 10 can be placed under solar panels S. Moreover, the present invention also encompasses a system in which a single system 10 is used with the solar panels S centered thereover.

As can also be seen, end plates 40 can also be provided. End plates 40 are dimensioned to connect onto the first and second elongated members 20 and 30 and to cover the (otherwise) open end of U-shaped channel 35 (i.e.: the “cable tray”) in second elongated member 30. Moreover, each end plate 40 may be dimensioned to wrap around a side and front portion of a solar panel positioned on top of the second elongated member, as shown. Specifically, each end plate 40 may include portions 41, 42, 43 and 44 that are each at right angles to one another with portion 43 positioned against the side of solar panel S and portion 44 positioned slightly across the front face of solar panel S, as shown.

As also seen in FIGS. 2A, 3A and 3B, center plates 50 may also be provided to secure solar panels S1 and S2 to system 10. Center plate 50 is dimensioned to connect onto first and second elongated members 20 and 30 and to cover a portion of the U-shaped channel 35 in second elongated member 30. In one embodiment, center panel 50 is dimensioned to wrap around a side and front portion of two spaced apart solar panels positioned on top of second elongated member 30, as shown. Specifically, each center plate 50 may comprise portions 51, 52, 53, 54, and 55 that are each at right angles to one another with portions 52 and 54 positioned against the sides of solar panels S1 and S2, and portions 51 and 55 positioned slightly across the front faces of solar panels S1 and S2, as shown.

In preferred embodiments, first elongated member 20 is made of Steel, Galvalume, Aluminum, Stainless steel, PVC or similar extrusion cladded with TPO, PVC, Hypalon, EPDM, sprayed polyurethane foam, modified Bitumen, building roofing, and the second elongated member 30 is made of Steel, Galvalume, Aluminum, Stainless steel, PVC or similar extrusion cladded with TPO, PVC, Hypalon, EPDM, sprayed polyurethane foam, modified Bitumen, building roofing. It is to be understood, however, that the present invention is not so limited. Other materials may be used. First elongated member 20 may be connected to a roof by heat welding of an strip of membrane on the cladded or extruded member 20 and then welding to the roof membrane, adhering member 20 to the roof, fastening through member 20 in to the roof, using weights to ballast member 20 on the roof, bolting to the roof or a combination of the above and second elongated member 30 is connected onto first elongated member 20 by bolting, metal fasteners, pop rivets, etc.

The present invention also provides method of mounting solar panels on a roof, comprising: mounting first elongated member 20 on a roof R; mounting a second elongated member 30 onto first elongated member 20, wherein U-shaped channel 35 in second elongated member 30 is received into U-shaped channel 25 in U-shaped channel 25 thereby forming a cable tray. Next, a solar panel S is positioned on top of second elongated member 30 and solar panel S is then secured onto the top of second elongated member 30.

Preferably, securing solar panel S onto the top of the second elongated member 30 comprises: wrapping edge 51/52 of center plate 50 around solar panel S; and connecting center plate 50 onto second elongated member 30 of system 10.

Referring lastly to FIG. 4, the present invention provides a solar panel roof mounting system 10A. System 10A comprises: a first elongated member 20A having a C-shaped channel 25A therein; and a second elongated member 30A having a U-shaped channel 35A therein. Second elongated member 30A is received down into first elongated member 20A (as shown by dotted lines) such that U-shaped channel 35A in second elongated member 30A is elevated with respect to the C-shaped channel 25A in first elongated member 20A.

It is to be understood that the present invention can be formed by bended or extruded, and is not limited to any particular shape or combination of shapes. For example, when using C-shaped channels, welding is easier, offering more room to move around the stand off. In contrast, when using U-shaped channels, stacking in easier.

In addition, the present invention is not limited to any particular system of fastening or anchoring (seismic or otherwise) to a roof surface. Moreover, ballast may optionally be added to the system to counter any wind uplift forces. 

1. A solar panel roof mounting system, comprising: a first elongated member having a U-shaped or C-shaped channel therein; and a second elongated member having a U-shaped or C-shaped channel therein, wherein the second elongated member is received into the first elongated member such that the U-shaped or C-shaped channel in the second elongated member is elevated with respect to the U-shaped or C-shaped channel in the first elongated member.
 2. The system of claim 1, wherein the first elongated member is a standoff.
 3. The system of claim 1, wherein the first elongated member is cladded or extruded.
 4. The system of claim 1, wherein the U-shaped or C-shaped channel in the second elongated member forms a cable tray.
 5. The system of claim 1, wherein each of the first and second elongated members comprise laterally extending portions that are connected to one another.
 6. The system of claim 5, wherein the laterally extending portion of the second elongated member is positioned on top of the laterally extending portion of the first elongated member.
 7. The system of claim 5, wherein the laterally extending portions of the first and second elongated members are interlocking.
 8. The system of claim 1, further comprising: an end plate dimensioned to connect onto the first and second elongated members and to cover an end of the U-shaped or C-shaped channel in the second elongated member.
 9. The system of claim 8, wherein the end plate is dimensioned to wrap around a side and front portion of a solar panel positioned on top of the second elongated member.
 10. The system of claim 1, further comprising: a center plate dimensioned to connect onto the first and second elongated members and to cover a portion of the U-shaped or C-shaped channel in the second elongated member.
 11. The system of claim 10, wherein the center plate is dimensioned to wrap around a side and front portion of two spaced apart solar panels positioned on top of the second elongated member.
 12. The system of claim 1, wherein the first elongated member is made of Steel, Galvalume, Aluminum, Stainless steel, PVC or similar extrusion cladded with TPO, PVC, Hypalon, EPDM, sprayed polyurethane foam, modified Bitumen, building roofing.
 13. The system of claim 1, wherein the second elongated member is made of Steel, Galvalume, Aluminum, Stainless steel, PVC or similar extrusion cladded with TPO, PVC, Hypalon, or EPDM, sprayed polyurethane foam, modified Bitumen, building roofing.
 14. The system of claim 1, wherein the first elongated member is connected to a roof by heat welding of an strip of membrane on the cladded or extruded member and then welding to the roof membrane, adhering the first member to the roof, fastening through first member in to the roof, using weights to ballast the first member on the roof, bolting to the roof or any combination of the above.
 15. A method of mounting solar panels on a roof, comprising: mounting a first elongated member on a roof, the first elongated member having a U-shaped channel therein; mounting a second elongated member onto the first elongated member, the second elongated member having a U-shaped or C-shaped channel therein, wherein the U-shaped or C-shaped channel in the second elongated member is received into the U-shaped or C-shaped channel in the first U-shaped or C-shaped channel thereby forming a cable tray; positioning a solar panel on top of the second elongated member; and securing the solar panel onto the top of the second elongated member.
 16. The method of claim 15, wherein securing the solar panel onto the top of the second elongated member comprises: wrapping an edge of a center plate around the solar panel; and connecting the center plate onto the second elongated member.
 17. The method of claim 16, further comprising: positioning a second solar panel on top of the second elongated member; and wrapping an opposite edge of a center plate around the second solar panel.
 18. The method of claim 15, wherein mounting a first elongated member on a roof comprises heat welding of an strip of membrane on the cladded or extruded member and then welding to the roof membrane, adhering the first member to the roof, fastening through first member in to the roof, using weights to ballast the first member on the roof, bolting to the roof or any combination of the above. 